ABSTARCT Due to the extreme costs associated with delivering cargo into space, there is a strong demand from

the space industry to increase the load capacity of the carriers. To keep the total weight of the system unchanged, an increase in load capacity must be accompanied by a decrease in the structural weight of the carrier. Just as within the aerospace and to some extent the automotive industry, the use of lightweight composite material to replace earlier all metal constructions have accelerated. There are still inevitably components that have to be made of metal and the interface between the different materials can then become an engineering challenge. Our project is to design the turbine exhaust duct (TED) of aerospace engine in a composite material in order to reduce the weight. Naturally this TED operates under very demanding conditions with cryogenic temperatures, high internal pressure, external structural loads and a pure hydrogen environment and the present TED is a robustly designed in cast Inconel 718, a nickel-based super alloy which is relatively heavy weight of about 7.7 kg when compared to other aerospace engine components. The flanges that form the interface with surrounding engine parts will still need to have a metal contact surface against the other components in order to assure a tight high pressure seal. For this reason a metal composite hybrid design is proposed where metal flanges are attached to a composite tubular body. The component geometry and the demand for a smooth inner surface leave adhesives as the only feasible option for the joints. This project investigates about the behavior of adhesively bonded joints when it is subjected to combined structural and thermal loadings between the turbine exhaust duct (TED) and attached titanium flanges, which is foremost priority before going for composite hybrid design. And also deals with the possibility of designing the Turbine Exhaust Duct (TED) of the aeronautical engine in composite materials like carbon fiber reinforced plastics (CFRP), EGlass/Epoxy, and Boron/Epoxy which leads to the reduction of weight of TED. The design model of TED is to be generated by using Pro/E Wildfire 5.0 and analyzed report is to be generated by using ANSYS 11.0 for the existing load condition during the engine run cycle.

CHAPTER: 1 INTRODUCTION: 1.1 THE TURBINE EXHAUST DUCT :( TED) A larger total thrust can be obtained from the engine if the gases are discharged from the aircraft at a higher velocity than is permissible at the turbine outlet. An exhaust duct is therefore added, both to collect and straighten the gas flow as it comes from the turbine and to increase the velocity of the gases before they are discharged from the exhaust nozzle at the rear of the duct. Increasing the velocity of the gases increases their momentum and increase the thrust produced. For the aerospace engines, the turbine exhaust duct is used for the liquid oxygen (LOX) and liquid hydrogen (LH2) fuel supply pump systems. In the Hydrogen Turbo-Pump (TPH), high pressure gaseous hydrogen (GH2) provides the power through a turbine connected to the pump drive shaft. After passing the turbine, the GH2 is passed through the Turbine Exhaust Duct (TED) in which it is divided into a main flow to power the Oxygen Turbo-Pump (TPO) and a secondary by-pass that can be passed on directly to the combustion chamber. The TED operates under very demanding conditions with cryogenic temperatures, high internal pressure, external structural loads and a pure hydrogen environment. Typically during an engine run cycle, the temperature inside the TED varies between room temperature and -140C and the internal pressures reaches as high as 10 MPa. Naturally this is very stressing on the component material and the present TED is a robustly designed in cast Inconel 718, a nickel-based super alloy.

Sample LH2 turbine data: Number of stages Nominal speed Nominal power output Mean gas diameter Mass flow Turbine inlet pressure Turbine inlet temperature Pressure ratio
2

1 91,000 rpm (max 102,000) 2500 kW (max 3700 kW) 120 mm 4.9 kg/s 180 Bar (max 232 Bar) 245 K (Max 325 K) 2:1

Fig no: 1.1 turbine exhaust duct. 1.2 COMPOSITE DETAILS: Composite materials are engineered materials made from two or more constituent materials that remain separate and distinct while forming a single component Generally, one material forms a continuous matrix while the other provides the reinforcement The two materials must be chemically inert with respect to each other so no interaction occurs upon heating until one of the components melts, an exception to this condition is a small degree of inter diffusion at the reinforcement-matrix interface to increase bonding Composites can be found in: The aerospace industry (structural components as well as engines and motors) Automotive parts (panels, frames, dashboards, body repairs) Sinks, bathtubs, hot tubs, swimming pools Cement buildings, bridges Surfboards, snowboards, skis Golf clubs, fishing poles, hockey sticks Trees are technically composite materials, plywood Electrical boxes, circuit boards, contacts everywhere.

Why Composites are Important? Composites can be very strong and stiff, yet very light in weight, so ratios of strength-toweight and stiffness-to-weight are several times greater than steel or aluminum. Fatigue properties are generally better than for common engineering metals. Toughness is often greater too. Composites can be designed that do not corrode like steel. Possible to achieve combinations of properties not attainable with metals, ceramics, or polymers alone. 1.3 CLASSIFICATION OF COMPOSITE:

Composites can be classified by their matrix material which includes: Metal matrix composites (MMCs) Ceramic matrix composites (CMCs) Polymer matrix composites (PMCs) or sometimes referred to as organic matrix composites (OMCs)

MMC - Metal Matrix Composites The matrix is relatively soft and flexible. The reinforcement must have high strength and stiffness. Since the load must be transferred from the matrix to the reinforcement, the reinforcement-matrix bond must be strong. MMC use: Two types of particulates (dispersion strengthened alloys and regular particulate composites) or long fiber reinforcements. PMC - Polymer Matrix Composites: The matrix is relatively soft and flexible The reinforcement must have high strength and stiffness Since the load must be transferred from matrix to reinforcement, the reinforcementmatrix bond must be strong CMC Ceramic Matrix Composites: The matrix is relatively hard and brittle. The reinforcement must have high tensile strength to arrest crack growth. The reinforcement must be free to pull out as a crack extends, so the reinforcementmatrix bond must be relatively weak.

Table: 1.1 types of composites:

1.4 COSTS OF COMPOSITE MANUFACTURE: Material costs -- higher for composites Constituent materials (e.g., fibers and resin) Processing costs -- embedding fibers in matrix Not required for metals Carbon fibers order of magnitude higher than aluminum Design costs -- lower for composites Can reduce the number of parts in a complex assembly by designing the material in combination with the structure Increased performance must justify higher material costs.

1.5 Types of Composite Materials: There are five basic types of composite materials: 1. Fiber. 2. Particle. 3. Flake. 4. Laminar or layered. 5. Filled composites.

Fig no: 1.2 types of composite materials (1) Fiber Composites: In fiber composites, the fibers reinforce along the line of their length. Reinforcement may be mainly 1-D, 2-D or 3-D. Figure shows the three basic types of fiber orientation. 1-D gives maximum strength in one direction. 2-D gives strength in two directions. Isotropic gives strength equally in all directions.

Fig no: 1.3 basic types of fiber orientation. (2) Particle Composites: Particles usually reinforce a composite equally in all directions (called isotropic). Plastics, cermets and metals are examples of particles. Particles used to strengthen a matrix do not do so in the same way as fibers. For one thing, particles are not directional like fibers. Spread at random throughout a matrix, particles tend to reinforce in all directions equally. Cermets: (1) OxideBased cermets: (E.g. Combination of Al2O3 with Cr) (2) CarbideBased Cermets: (E.g. Tungstencarbide, titaniumcarbide) (3)Metalplastic particle composites: (E.g. Aluminum, iron & steel, copper particles) (4)Metalinmetal Particle Composites and Dispersion Hardened Alloys: (E.g. Ceramicoxide particles)
8

3. a.Flake Composites 1 Flakes, because of their shape, usually reinforce in 2-D. Two common flake materials are glass and mica. (Also aluminum is used as metal flakes)

Fig no :1.4 Flake Composites. b.Flake Composites -2 A flake composite consists of thin, flat flakes held together by a binder or placed in a matrix. Almost all flake composite matrixes are plastic resins. The most important flake materials are: Aluminum Mica

1. 2.

3. Glass

c.Flake Composites -3
Basically, flakes will provide: Uniform mechanical properties in the plane of the flakes Higher strength Higher flexural modulus Higher dielectric strength and heat resistance Better resistance to penetration by liquids and vapor Lower cost

4.a.Laminar Composites 1: Laminar composites involve two or more layers of the same or different materials. The layers can be arranged in different directions to give strength where needed. Speedboat hulls are among the very many products of this kind.

b.Laminar Composites 2:
Like all composites laminar composites aim at combining constituents to produce properties that neither constituent alone would have. In laminar composites outer metal is not called a matrix but a face. The inner metal, even if stronger, is not called reinforcement. It is called a base.

c.Laminar Composites 3:
We can divide laminar composites into three basic types: Unreinforcedlayer composites

(1) AllMetal (a) Plated and coated metals (electro galvanized steel steel plated with zinc) (b) Clad metals (aluminumclad, copperclad) (c) Multilayer metal laminates (tungsten, beryllium) (2) MetalNonmetal (metal with plastic, rubber, etc.) (3) Nonmetal (glassplastic laminates, etc.) a. Reinforcedlayer composites (lamina and laminates) b. Combined composites (reinforcedplastic laminates well bonded with steel, aluminum, copper, rubber, gold, etc.)

10

d.Laminar Composites 4:
A lamina (laminae) is any arrangement of unidirectional or woven fibers in a matrix. Usually this arrangement is flat, although it may be curved, as in a shell. A laminate is a stack of lamina arranged with their main reinforcement in at least two different directions.

Fig no :1.5 Laminar Composites. 5.Filled Composites: There are two types of filled composites. In one, filler materials are added to a normal composite result in strengthening the composite and reducing weight. The second type of filled composite consists of a skeletal 3-D matrix holding a second material. The most widely used composites of this kind are sandwich structures and honeycombs. Combined Composites: It is possible to combine several different materials into a single composite. It is also possible to combine several different composites into a single product. A good example is a modern ski. (combination of wood as natural fiber, and layers as laminar composites)

Fig no: 1.6 Combined Composites.

11

1.6 Forms of Reinforcement Phase: Fibers cross-section can be circular, square or hexagonal Diameters --> 0.0001 - 0.005 Lengths --> L/D ratio 100 -- for chopped fiber much longer for continuous fiber Particulate Flakes flat platelet form small particles that impede dislocation movement (in metal composites) and strengthens the matrix For sizes > 1 mm, strength of particle is involves in load sharing with matrix

Fiber Reinforcement: The typical composite consists of a matrix holding reinforcing materials. The reinforcing materials, the most important is the fibers, supply the basic strength of the composite. However, reinforcing materials can contribute much more than strength. They can conduct heat or resist chemical corrosion. They can resist or conduct electricity. They may be chosen for their stiffness (modulus of elasticity) or for many other properties. 1.7 Types of Fibers: The fibers are divided into two main groups: Glass fibers: There are many different kinds of glass, ranging from ordinary bottle glass to high purity quartz glass. All of these glasses can be made into fibers. Each offers its own set of properties. Advanced fibers: These materials offer high strength and high stiffness at low weight. Boron, silicon, carbide and graphite fibers are in this category. So are the aramids, a group of plastic fibers of the polyamide (nylon) family.
12

Fibers Glass: Fiberglass properties vary somewhat according to the type of glass used. However, glass in general has several wellknown properties that contribute to its great usefulness as a reinforcing agent: Tensile strength Chemical resistance Moisture resistance Thermal properties Electrical properties

There are four main types of glass used in fiberglass: Aglass Cglass Eglass Sglass

Most widely used fiber Uses: Piping, tanks, boats, sporting goods Advantages: Corrosion resistance Low cost relative to other composites, Low cost

Disadvantages: Types: E-Glass - electrical, cheaper S-Glass - high strength Relatively low strength High elongation Moderate strength and weight

13

Fibers - Aramid (Kevlar, Twaron): Uses: High performance replacement for glass fiber

Examples: Armor, protective clothing, industrial, sporting goods

Advantages: Higher strength and lighter than glass More ductile than carbon

Fibers Carbon: 2nd most widely used fiber

Examples: aerospace, sporting goods

Advantages: Properties: Standard modulus: 207-240 Gpa Intermediate modulus: 240-340 GPa High modulus: 340-960 GPa Diameter: 5-8 microns, smaller than human hair Fibers grouped into tows or yarns of 2-12k fibers high stiffness and strength Low density Intermediate cost

14

Fibers -- Carbon (2): Types of carbon fiber: vary in strength with processing Trade-off between strength and modulus

Intermediate modulus: PAN (Polyacrylonitrile)

Fiber precursor heated and stretched to align structure and remove non-carbon material High modulus: made from petroleum pitch precursor at lower cost much lower strength

Fibers Others: Boron High stiffness, very high cost Large diameter - 200 microns Good compressive strength

Polyethylene - trade name: Spectra fiber Textile industry High strength Extremely light weight Low range of temperature usage

Fibers -- Others (2) Ceramic Fibers (and matrices) Very high temperature applications (e.g. engine components) Silicon carbide fiber - in whisker form. Ceramic matrix so temperature resistance is not compromised Infrequent use
15

Fiber Material Properties Fig no: 1.2 material properties of typical fibers.

16

CHAPTER-2
2.1 ADHESIVE INTRODUCTION: There is an apparent growth of joining metals to composites, especially in the aeronautics. The reasons are the attractive mechanical properties (high strength, high stiffness, resistance to the propagation of structural damage) of both materials and also the reduction of costs. Because composites are almost always used for their superior mechanical properties, the need for joints that can sustain high loads and stresses is extremely important. Organic/polymeric, metallic, inter metallic, ceramic, and carbon types of composites all pose different problems. One must always keep in mind the compatibility of chemical, physical and mechanical properties of all materials involved in joints. There are generally three options for joining metals to composites: (1) Mechanical Fastening, (2) Adhesive bonding and (3) rivet-bonding. 2.2 General description of Adhesive Bonding: Adhesive bonding is the process of joining materials with the aid of a substance, acting as a chemical agent, capable of holding those materials together by surface attachment forces. The materials being joined are called the adherend, while the bonding agent is called the adhesive. The forces that enable the surface attachment arise from one or more of several fundamental sources, most of which are chemical in origin, but some of which can be mechanical or even electrostatic. The adhesive bonding is fundamentally a chemical bonding process. Adhesives transmit stresses from one element of a joint (or one adherend) to another in such a way that the stresses are distributed more uniformly than in most mechanical method and welds.

17

2.3 Theories for Adhesive Bonding: Four theories explain the process of adhesive bonding by explaining the underlying Phenomena leading to adhesion: 1) The electrostatic theory of adhesion (based on electrostatic forces between adherend and adhesive) 2) The diffusion theory of adhesion (based on partial solubility of adherend and Adhesive) 3) The mechanical theory of adhesion (based on adhesives penetration into the Microscopic asperities of adherend, resulting in mechanical interlocking.) 4) The adsorption theory of adhesion.

Fig no: 2.1 structure of adhesive bonding. 2.4 Types of Adhesives Lists the various forms of adhesive bonding 1. Natural Adhesives: Animal-based adhesives (e.g. casein, collagen, gelatin, lac) Plant-based adhesives (e.g. pitch, natural rubbers, asphalt) Mineral-based adhesives (e.g. sodium silicate, water glass, mineral-based sol-gels, calcium carbonate) 2. Synthetic Adhesives: Synthetic Organic Adhesives Chemically-activated adhesives (e.g. anaerobic, cyanoacrylates, epoxies)
18

In many applications adhesively bonded joints are more suitable than traditional joining techniques such as mechanical fastening, especially for components made from composite or polymeric materials, because they can provide uniform distribution of load, resulting in better damage tolerance and excellent fatigue life. Whereas adhesively bonded joints and bonded repairs made to cracked metallic Structures have been continuously receiving attention in the aerospace industry for the purpose of enhancing fatigue resistance and restoring the stiffness and strength of damaged/cracked structures, the effective use of adhesive bonding technology in primary structural members is still in its infancy. Because of the involvements of many geometric, material and fabrication variables, and complex failure modes And mechanics presented in the joints, a deep understanding of the failure behavior of adhesively bonded joints, particularly under combined loading conditions, is needed in order to fully achieve the benefits of adhesive bonding. There are several Typical failure modes associated with adherends and adhesive in adhesively bonded composite repairs including substrate yielding; patch fiber breaking in tension, fiber failing in compression, adhesive shearing, substrate-adhesive peeling, patch-adhesive peeling, patch inter laminar peeling, and patch inter laminar shearing. Since substrate yield is not a catastrophic failure mode, an optimal design will focus on other failure modes associated with the patch and adhesive. The failures in adhesively bonded joints are mainly of two types, adhesive and cohesive; occurring mainly due to interfacial (adhesive) cracking, also called deboning, at geometric boundaries due to stress concentrations, or resulting from faulty joining in fabrication. Wellbonded joints should fail within the adhesive (cohesive) or within the adherends (inter laminar failure) when broken apart. Failure at the adherend-adhesive interface (interfacial failure) generally indicates that the bond was not performed properly. Stress based concepts provide a realistic description of the stresses and strains and information on the physical cause for material rupture. In order to explain the mechanical behaviors of adhesively bonded joints and develop a failure prediction method it is useful to be able to predict the stresses acting in the joint. Nominal adhesive peel and shear stresses are related to mode-I and mode-II deformation of the adhesive layer, respectively. Stress-based approaches, which focus on indicating both shear and normal (peel) stresses through standard lap shear tests, have been the subject of a vast amount of
19

researches. Adhesive bonding usually requires curing of adhesive at temperature higher than applied condition. When two adherend have dissimilar material properties and subsequently having mismatch coefficients of thermal expansions, the curing process create residual stress in jointed materials, such situations generally are produced when one adherend is made of composite material and another is metallic material. Composite patch commonly used in aerospace industry particularly in cracked metallic structures, are subjected to thermal loading due to difference in the operating temperature of the aircraft in flight time or bonding process due to curing of the adhesive. Accurate computational thermal stress analysis is particularly important for estimation of the service life of bonded joints and repairs. In this study, a finite element thermal stress analysis was conducted in order to investigate the behavior of adhesively bonded joints using double-lap joints. 1. Major classes of adhesive: Adhesives can be classified by several methods, none of them perfect, such as the way they set (that is, transform from a wetting liquid to a load-bearing solid), the way they are used in assembly, or by chemical type. The strongest adhesives set by chemical reaction. Less strong types harden by physical change, cooling from a melt or evaporation of a solvent. The major classes are described below. 2. Anaerobic: Anaerobic adhesives cure when in contact with metal, and the air is excluded For Example, when a bolt is home in a thread. They are often known as 'locking compounds', being used to secure, seal and retain turned, threaded, or similarly close fitting parts. They are based on synthetic acrylic resins. 3. Cyanoacrylates: Cyanoacrylate adhesives cure through reaction with moisture held on the surface to be bonded. They need close fitting joints and usually solidify in seconds. Cyanoacrylates are suited to small plastic parts and to rubber. They are a special type of acrylic resin.

20

4. Toughened Acrylics: Toughened acrylics are fast curing and offer high strength and toughness. Both one-part and two-part systems are available. In some two-part systems, no mixing is required because the adhesive is applied to one substrate, the activator to the second substrate, and the substrates joined. They tolerate minimal surface preparation and bond well to a wide range of materials. 5. Epoxies: Epoxy adhesives consist of an epoxy resin plus a hardener. They allow great versatility in formulation since there are many resins and many different hardeners. Epoxy adhesives can be used to join most materials. Epoxies have good strength, do not produce volatiles during curing and have low shrinkage. However, they can have low peel strength and flexibility and are brittle. Epoxies adhesives are available in one-part, two-part and film form and produce extremely strong durable bonds with most materials. 6. Polyurethanes: Polyurethane adhesives are chemically reactive formulations which may be one-part or two-part systems and are usually fast curing. They provide strong impact-resistant joints and have better low-temperature strength than any other adhesive. Polyurethanes are useful for bonding glass fiber reinforced plastics (GRP). The fast cure usually necessitates applying the adhesives by machine. They are often used with primers. 7. Silicones: Silicones are not very strong adhesives but are known for their flexibility and high Temperature resistance. They are available in single or two-part forms. The latter Function like the two-part epoxies, the former like the single-part polyurethanes. When the single-part adhesives cure they liberate either alcohol or acetic acid (the familiar smell of vinegar).They is often used as bath and shower sealants. Their adhesion to surfaces is only fair but, like their flexibility, their durability is excellent. The two-part versions need a hardening agent to be mixed into the resin. Two forms are available - those which liberate acid on curing and those that do not. As might be anticipated, the two-part adhesive systems give a better cure in thick sections than do the single-part types.
21

8. Phenolics: Phenolics were the first adhesives for metals and have a long history of successful use for joining metal to metal and metal to wood. They require heat and pressure for the curing process. 9. Polyamides: Polyamides are mainly used in applications which exploit their ability to withstand Temperature up to 350C. They are available as liquids or films and although they have good strength retention at high temperature, they have the disadvantage of being expensive and difficult to handle. The following adhesives undergo a physical change and are less effective at forming an adhesive bond. 10. Hot-melts: Hot-melts are based on modern thermoplastics and are used for fast assembly of Structures designed to be only lightly loaded. 11. Plastisols: Plastisols are modified PVC dispersions which require heat to harden. The resultant joints are often resilient and tough. 12. Rubber Adhesives: Rubber adhesives are based on solutions of latexes and solidify through loss of the Solvent medium. They are not suitable for sustained loadings. 13. Polyvinyl acetate (PVAs): Vinyl acetate is the principal constituent of the PVA emulsion adhesive. They are suited to bonding porous materials, such as paper or wood, and to general packaging work. 14. Pressure-sensitive adhesives: Pressure-sensitive adhesives are suitable for use as tapes and labels and, although they do not solidify, are often able to withstand adverse environments. This type of adhesive is not suitable for sustained loadings.
22

15. Adhesive selection principles: Selection of an adhesive for a particular application may at first appear daunting. However, there are many sources of assistance, such as adhesive suppliers, expert Consultants and computer-based selection systems. Since none of these sources can be comprehensive, there are some guiding principles which will help in any decision-making process. The joint type, joint function, in-service conditions and manufacturing issues must all be considered. But by defining a few key performances or manufacturing requirements, this will quickly deselect most potential adhesive types.

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CHAPTER-3
3.1 PROBLEM DEFNITION: The TED operates under very demanding conditions with cryogenic temperatures, high internal pressure, external structural loads and a pure hydrogen environment. Typically during an engine run cycle, the temperature inside the TED varies between room temperature and -140C and the internal pressures reaches as high as 10 MPa. Naturally this is very stressing on the component material which causes deformation of adhesive joint between TED and Titanium Flange. And the present TED is a robustly designed in cast Inconel 718, a nickel-based super alloy which is relatively heavy weight of about 7.7 kg when compared to other aerospace engine components. 3.2 EXISTING MATERIAL PROPERTIES: FOR DUCT: INCONEL alloy 718 (UNS N07718/W.Nr. 2.4668) is a high-strength, corrosion-resistant nickel chromium material used at -423 to 1300F. Typical composition limits are shown in Table 1. The age-harden able alloy can be readily fabricated, even into complex parts. Its welding characteristics, especially its resistance to post weld cracking, are outstanding. The ease and economy with which INCONEL alloy 718 can be fabricated, combined with good tensile, fatigue, creep, and rupture strength, have resulted in its use in a wide range of applications. Examples of these are components for liquid fueled rockets, rings, casings and various formed sheet metal parts for aircraft and land-based gas turbine engines, and cryogenic tankage. It is also used for fasteners and instrumentation parts. 3.3 Inconel 718 Nickel-Chromium Alloy in (TED): Inconel 718 is a Nickel-Chromium alloy being precipitation hardenable and having high creep-rupture strength at high temperatures to about 700C (1290F). It has higher strength than Inconel X-750 and better mechanical properties at lower temperatures than Nimonic 90 and Inconel X-750

24

Chemical Composition of Inconel 718: The compositional range for Inconel 718 is provided in the table1.2 below. Table:3.1 Chemical Composition of Inconel 718: Element Ni+Co Cr Fe Nb+Ta Mo Ti Al Typical Properties of Inconel 718: Table:3.2 Typical properties of Inconel 718 are covered as follows: Property Density Melting point Co-Efficient of thermal Expansion Modulus of rigidity Modulus of elasticity Relevant Standards: Inconel 718 is covered by the following standards: AMS 5663 AMS 5832 AMS 5962 AMS 5662 ASTM B637 Metric 8.19 g/cm3 1336 C 13.0m/m.(20-100C) 77.2 KN/mm2 204.9 KN/mm2 Imperial 0.296 lb/in3 2437 F 7.2x106in/in.F (70-212 F) 11197 ksi 29719 ksi Content 50 - 55 % 17 - 21 % BAL 4.75 - 5.5 % 2.8 - 3.3 % 0.65 - 1.15 % 0.2 - 0.8 %

25

Applications of Inconel 718: Inconel 718 typically finds application in: Gas turbines Rocket motors Space craft Nuclear reactors and pumps.

3.4 ABOUT TITANIUM FLANGE: ATI Ti-6Al-4V, Grade 5 Titanium Alloy (UNS R56400) INTRODUCTION: ATI Ti-6Al-4V, Grade 5 alloy (UNS R56400) is the most widely used titanium grade. It is a two phase + titanium alloy, with aluminum as the alpha stabilizer and vanadium as the beta stabilizer. This high-strength alloy can be used at cryogenic temperatures to about 800F (427C). ATI Ti-6Al-4V, Grade 5 alloy is used in the annealed condition and in the solution treated and aged condition. Some applications include: compressor blades, discs, and rings for jet engines; airframe and space capsule components; pressure vessels; rocket engine cases; helicopter rotor hubs; fasteners; critical forgings requiring high strength-to-weight ratios. Grade 5, also known as Ti6Al4V, Ti-6Al-4V or Ti 6-4, is the most commonly used alloy. It has a chemical composition of 6% aluminum, 4% vanadium, 0.25% (maximum) iron, 0.2% (maximum) oxygen, and the remainder titanium.[5] It is significantly stronger than commercially pure titanium while having the same stiffness and thermal properties (excluding thermal conductivity, which is about 60% lower in Grade 5 Ti than in CP Ti).[6] Among its many advantages, it is heat treatable. This grade is an excellent combination of strength, corrosion resistance, and weld and fabric ability

26

Technical information - mechanical properties of titanium: Table: 3.3: mechanical properties of titanium: Yield Strength (0.2%) (Ksi) 120 Tensile Strength (Ksi) 130 Reduction in Area (%) 20

ALLOY Grade5 (6AL-4V)

Elongation (%) 10

Hardness

28-34Rc

3.5 ADHESIVE JOINT: Traditionally in engineering, structural joining has been synonymous to riveting, bolting and other purely mechanical fastening together with welding or soldering in the case of metallic construction materials. Up until the introduction of the polymeric adhesives around the time of the Second World War these were the only means of joining available but with the increased use of plastics, and more importantly fiber reinforced composite materials, the use of adhesive joining has increased rapidly and is today found in numerous applications with different material configurations. The reason for the increased use of adhesive joining is that it can provide a number of structural and economical advantages over more traditional methods of joining, of course assuming that the joint is properly designed. One of the most important features to keep in mind during the initial joint design is that adhesive joints are very strong in shear, but unfortunately are very vulnerable to normal stresses (in the context of adhesives commonly referred to as peel stresses). Provided that the joint is loaded in its favorable direction, some of the advantages are High strength to weight ratio Stresses distributed evenly over the joint width No drilled holes needed Weight and material cost savings Improved aerodynamic surface design Superior fatigue resistance Outstanding electrical and thermal insulation
27

As with any other technology, there are also limitations to consider when using adhesives in engineering. Elevated temperatures and high humidity can result in negative effects on the strength of some types of adhesives, especially when under continuous stress, and as with other polymeric materials, creep effects must be considered. Even though manufacturing procedures such as drilling, machining and riveting can be avoided when using adhesive fastening, this is replaced with a need for careful surface preparation prior to bonding, especially when using metal adherends. When designing an adhesively bonded structure, one of the first questions that arise is the cross-sectional geometry of the joint. Figure shows a comprehensive overview of the most commonly used engineering adhesive joints and the terminology of the various adherend shapes.

Fig no: 3.1 Overview of a loaded SLJ with and without an adhesive spew fillet. Areas sensitive to crack initiation are marked in red. 3.6 ADHESIVE PROPERTIES: Table: 3.4: EA9394 properties units& values: S.NO 1. 2. 3. 4. properties Youngs modules Poisson ratio Thermal conductivity Co-efficient of thermal expansion units n/mm2 w/m.k m/c Value 4.071e3 0.37 0.331 55.6

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3.7 PROPOSED ALTERNATIVE MATERIAL FOR TED: DUCT MATERIAL: Here the proposed material is changed for only the duct design alone and the material is listed as follows: Three composites used are: Boron / Epoxy E Glass Polyester Resin Carbon/epoxy

Table: 3.5: turbine exhausts duct material (TED) properties & values: E-glass Polyester resin 3.4e10 Carbon epoxy

S. no

Property Young's Modulus X direction Young's Modulus Y direction Youngs Modulus Z direction Major Poisson's Ratio XY Shear Modulus XY

units

Boron /Epoxy

pa

281.86e9

pa

10.88e9

6.53e9

1.34e 11

pa

10.88e9

6.3e9

0.2451

0.217

0.3

pa

67.49

2.433e9

Density

Kg/m3

2249

2100

1600

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3.8 OBJECTIVE OF THE PROJECT: The objective of the project is to analyze the adhesive joint itself to identify the critical stress in parts for the existing load cases and also to reduce the weight by using composite material. Here the duct is to be designed and analyzed by applying various material properties such as cast INCONEL 718 and composites materials like carbon fiber reinforced plastics, Glass Epoxy, Boron epoxy, and also adhesive bond structure between TED and Flange is to be designed as a thin layer and it is analyses by applying various adhesive properties. 3.9 METHODOLOGY: The duct and flange is to be designed as the 3d modeling by using Pro/E Wildfire 5.0.with respect to their existing design specimen. The adhesive joint is created as thin layer in 3d modeling. Than the duct, flange and titanium is to be assembled. The assembled TED is converted into as a single part model through IGES format conversion. The FEA is done to be for imported IGES modeling by using ANSYS. The material properties value is applied for the meshed model after the report is generated.

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